Godrej Industrial Safety Essay Example For Students

Godrej Industrial Safety Essay SARASWATI COLLEGE OF ENGINEERING DEPARTMENT OF MASTER OF MANAGEMENT STUDIES. Research paper: (Research Methodology Project) Title: Case Study On Godrej Industrial Safety Guide: Prof. Priyadarshini Poddar Name of Author: Chetan Jagtap Date: 22nd February 2010 ABSTRACT Man and machine are two important ingredient of industrial safety. Men need machine which many times bring hazard and accidents this has created the need of industrial safety. It is more important to minimize or eliminate the contact between men and machine are the product of engineering and therefore engineeri-ng occupies the pioneering place in industrial safety. The Project objective is to learn and practically implement the industrial safety theory. To study and analyze safety activities and performance existing in the plant. The purpose of this project is to analyze the accident rate of the plant various safety practices used by the company. Personal Protective Equipment Safe practices is the key to eliminate the hazard accident. The primary data collected from Godrej plant Safety Report. INTRODUCTION TO SAFETY IN ENGINEERING INDUSTRY Man and machine are to important ingredient of industrial safety. Men need machine which many times bring hazard and accidents this has created the need of industrial safety. It is more important to minimize or eliminate the contact between men and machine machine are the product of engineering and therefore engineering occupies the pioneering place in industrial safety. Without engineering industries no machine and no mass production is possible. Section 14, 21 to 26, 28 to 35, 87, 88, and IVA of factory act 1948 and rule made under these section by Gujarat factories rule provides safety measures machinery, processes, and accidents. The provision are for safety from dust , machinery in motion, power cutting devices, self acting machine, carrier of new machinery, hoist and lifts, lifting machine, revolving machine, floor, stairs, means of access, excessive weight, protection of eyes and hazardous processes in ferrous and non ferrous metallurgical industries and foundries, core industries, grinding or glazzing of metal , electroplating of metal. Godrej at a Glance†¦ In the year 1997, Godrej Boyce celebrated their centenary year. This dynamic organization has progressed tremendously since its inception and has been gaining strength consistently. Quality is the hallmark of the all the Godrej products and any product with the Godrej mark represent quality, dependability satisfaction to its customers. What now is a gainful industrial organization was a brainchild of Mr. Ardeshir Godrej, which through the help dedicated men with tremendous foresight and finely honed engineering and marketing skills, has become one of the biggest houses in India. His brother Mr. Phirozshah Godrej under his leadership the organization grew and diversified further carried on the founders pioneering work. In 1905 Godrej built his first safe thus vetting foot in to the security equipment business which at eight years from its century has become 100 crores turnover division with almost no competition in the Indian market and global presence in this field. Former expansion came in 1923 with the introduction of steel shelves with industrialization growing at a brisk space need for office equipment like chairs, tables, filing cabinets and movable partition system, etc. was felt in 1937. In 1955, started the production of one item without which no office in India could be completed The Typewriters. This indigenously built all Indian typewriters has made Godrej one of the leading manufactures of typewriters in India. Realizing todays need this branch has also set foot in the field of electronics typewriter, projectors and basic models of word processor. The next Godrej product to sweep the Indian market was the steel cupboard in 1958. This product to have become a regular sight in houses homes. This was then followed by another product, which passed many a milestone since its conception and which to have become a household name The Godrej Refrigerator. The manufacture of a range of hospital furniture. The steel locks for Libraries in 1936, designed to keep up with modern library methods, canteens equipment made to the latest design in 1951 and auditorium chairs in 1954, make contribution of Godrej to national welfare. In 1953, Godrej started manufacturing tools crib and cabinets for systematic adaptable, fully accessible storage. In order to keep up with modern with growing needs of industries, Godrej entered another progressive phase in 1957 with manufacture of ink tool for internal as well as external use. The first Godrej Mechanical Press Breaks were made in 1942 and son almost every plant at Godrej was using this. The long life, quality and performance at these miles are reflected in the excellence of Godrej products. In 1960, in collaboration with M/s. Clart International, started the manufacturing of Forklift trucks, both types which can be operated by fuel and electric with capacity ranging from one ton to sixteen tones which have item and again proved there worth as a rigged and versatile material handling equipment with the field of welding technology gaining importance and recognition Godrej has setup one of the most modernized units for the fabrication of large pressure vessels and other equipment. The most recent achievement by Godrej was made when it acquired the ISO 9000, ISO 9001 and ISO 14000 certificate which former reinforced the rest of not only the Indian market but also the global market in the product of Godrej. Today Godrej employee over 15,000 people and has grown in to a multi-crores professionally managed group with far reaching service and distribution network. Economy and Services† are being the main motto of Godrej they have already diversified in to field of Indian industry thus helping in the economic growth of the country. Production range of the Company at Vikhroli†¦ |Plant No. Name of the Plant / Division |Product | | | | | |1 |Steel Processing Plant |Steel Al blanks | | | | | |2 |GODREJ Appliances Limited |Refrigerators, etc; | | |O. E. Division (Furniture Business) | | |3 | |Furniture | | |GODREJ Applications Limited | | |4 | | | | |Tool Room Division | | |5 | |External Internal jobs | | |Storage | | |7 | | | | |Machine Tool Division | | |8 | |Presses Press Tool | | |O. E. Division (Storewel Business) | | |9 | |Stonewell | | |Stonewell solution Business | | |10 | |Storage solutions | | |O. E. Division (Furniture Business) | | |11 | |Chairs | | |Precision Equipment Division | | |12 | Reactors, Pressure vessels, | | |Material Handling Equipment Division |Fork Lift Trucks | |13 | | | | |Security Equipment Division | | | | |Security equipments | |14 | |Like Safes, Strong Doors, Avanti Doors, etc. | | | | | | |Locks | | |Locks Division | | | | | | |15 | | | | | | | | | | | OBJECTIVES AND METHODOLO RESEARCH METHODOLOGY : Research can be defined as a systemized effort to gain new knowledge. A research is carried out by different methodologies which have their own pros and cons. Research methodology is a way to solve research in study and solving research problems along with logic behind them are defined through research methodology. Thus while talking about research methodologies we are not only talking of research methods but also consider the logic behind the methods. We are in context of our research studies and explain why it is being used a particular method or technique and why the others are not used. So that research result is capable of being evaluated either by researcher himself or by others. ASSUMPTIONS: 1. It has been assumed that sample of 25 workers represents the whole population. 2. The information given by the workers of Godrej is unbiased. COLLECTION OF DATA: This research is solely based on primary research done by means of questionnaires targeted to workers. The sample size is 25. Survey has been conducted in Godrej at Vikhroli. Referred Various Books links related to Industrial Safety Godrej industry. RESEARCH METHODOLOGY RESEARCH OBJECTIVE QUESTIONNAIRE PREPARATION REASEARCH METHOD QUALITATIVE METHOD (QUESTIONNAIRE) DATA INTERPRETATION DATA ANALYSIS CONCLUSION Introduction to Plant – 17 Plant no. 17 is one of the plants of the O. E. Division (Office Equipment Division). O. E. Division is the biggest division in Godrej Boyce Mfg. Co. Ltd. Under the O. E. Division falls business like: †¢ Office Furniture Business. †¢ Security Equipment Business. †¢ Storewel. †¢ Strong Solutions Group. Steel Procurement Plant. Plant no. 17 is manufacturing the Security Equipments. Godrej is the first Indian Company to manufacture safes of quality comparable to that other well-known international makes. If viewed from a board perspective plant-17 consists of mainly two divisions, Manufacturing and Marketing. The manufacturing line mainly consists of the assemblies. They are: †¢ Assembly I (RPE Group) †¢ Assembly II (SDLC Group) †¢ Assembly III (Safe Group) †¢ Assembly IV (Strong Door) †¢ Assembly V (Avanti home security doors/Fire Doors) †¢ Assembly VI (ATM) Various Products manufactured in Plant 17 are: †¢ Defender Plus Safes †¢ Strong Door Safe Deposit Locker Cabinet †¢ Fire Resisting Record Cabinet and Filling Cabinet †¢ Dataline datasafe,Dataline ‘M’,Matrix safe †¢ Avanti Home Security Doors ( Recently introduced in market) †¢ Electronic Safes SAFETY MANAGEMENT SYSTEM The main function of the safety department is to advice assists the management in the fulfilment of its obligation concerning prevention of personal injuries and maintaining safe working environment. The safety department conducts various training programme s for the employees assists the management in functioning of safety committee. General safety training such as Basic Principles of Accident prevention, Fire fighting prevention, Housekeeping etc. is given to all employees. The specific training such as Welding safety, Safety in power presses etc. is given to the employees performing specific work. The purchase department is advised in the matter relating to selection of personal protective equipment. The departments of the plant are advised in planning organising measures necessary for the effective control of personal injuries. Company’s OCCUPATINAL, HEALTH AND SAFETY POLICY: Our management firmly believes that people constitute the principal asset of our business and industry. A company can gain competitive advantage by supplying superior products services. The Necklace EssayNO |YEAR |2005-2006 |2006-2007 |2007-2008 | |1 |REPORTABLE |8 |3 |1 | |2 |NON REPORTABLE |56 |69 |50 | Analysis based on TIME |SR. No |Year |7. 00-9. 00 |9. 00-11. 00 |11. 30-13. 00 |13. 00-14. 00 |14. 00-15. 30 |IInd shift | |1. |2005-06 |15 |18 |9 |7 |3 |5 | |2. |2006-07 |15 |21 |6 |12 |4 |8 | |3. |2007-08 |13 |13 |7 |6 |4 |7 | OBSERVATION: 1. It is observed that most of the accident had taken place early in the morning session. It might be because the workers are not that active in morning session as compare to later part of the day. 2. The reason for the accident may be to the negligence, inadequate knowledge, or due to the unsafe act to complete the job before time. 3. Accident may be due to poor illumination during night shift or in the work place. SUGGESTION: 1. The work area should be properly illuminated. 2. Before getting to the job in morning their should be a practice of making the workers some sort of exercise so that they should be alert at the time of job. 3. Standard operating procedure should be given to carry out the job. 4. If required the workers should be given frequent intervals for rest. Accident analysis based on FR, SR, FSI SR NO |YEAR |FR |SR |FSI | |1. |2003-2204 |5 |153 |1 | |2. |2006-2007 |1. 81 |63. 98 |0. 34 | |3. |2007-2008 |0 |0 |0 | Accident analysis based on Body part injury wise | |Body Part | Year |Face |Finger |Leg |Arm |Head |Wrist |Chest |Elbow |Back |Abdomen | |2005-2006 |3 |37 |9 |4 |5 |1 |1 |2 |1 |1 | |2006-2007 |3 |41 |11 |7 |5 |2 |0 |1 |1 |1 | |2007-2008 |3 |28 |6 |9 |3 |2 |0 |0 |0 |0 | | HAZARD IDENTIFICATION RISK ANALYSIS ( HIRA) Before implementation of OHSAS 18001 accident investigation is done after an accident happens. But in OHSAS 18001 Hazard Identification Risk Analysis is done before an accident happens. HIRA Chart (Hazard Identification Risk Analysis) visualizes possible hazards involved in each activity done by the workmen. This helps in minimizing or completely eliminating the hazards, before any accident occurs. ? ACCIDENT: It is any unplanned, undesirable unaccepted incident, which causes damage or injury within or out of plant. TYPES OF ACCIDENT: 1) Reportable accident 2) Non-reportable accident 3) Near miss accident INCIDENT : An incident is an event which realizes the damage potential of a hazard. Obviously, an incident has to be relevan t to the hazard. Incidents can be quite simple, but often they are complex, with a number of events combining to cause the incident. For example, an escape of corrosive substance could, under different consequences lead to: ? Human exposure ? Environmental exposure ? Equipment exposure and we could construct event trees which would describe events leading to any of these three. Incidents cannot only vary in type but in frequency, and in risk analysis the frequencies and the probabilities of events leading to an incident are assessed to determine risk. CONCLUSION RECOMMENDATION : Though the safety standards of Godrej And Boyce Mfg. Co. Ltd fulfill the requirement, the safety system may be improved by adopting certain recommendations. Following are the points, which are recommended: ? Safety induction training should be given to each and every workers. ? Work permit system should be strictly followed. ? PPE should be provided to each and every employee. ? To improve moral and efficiency of workers by creating safe environment. Looking to huge strength of departmental and central employees, more number of training programmed in safety, first aid and motivation need to be conducted frequently to cover each employee of organization. ? More number of safety posters, films, and design boards are required to be displayed to create interest of workers in safety. ? Short cut methods, improper use of tools, tackles, etc. should be discouraged by one and all. ? Checklist should be developed for all activities and items of work involved in plant. ? Only authorized workers should be allowed to drive the fork lift trucks. ? Safety suggestion box shall be provided in each section for getting better feed back/ suggestion about the safety issues related to the plant from the workers. ANNEXRE : (QUESTIONAIRE FOR WORKERS) Name: . Company Name: . 1) If you come across a hazard in your workplace, you do not need to report it unless you are a member of the Safety Committee or are the dedicated Safety Officer. TRUE or FALSE 2) You should always take time to assess hazards when starting in a new workplace. TRUE or FALSE 3) Good housekeeping is everyone’s responsibility. TRUE or FALSE 4) Laying electrical cords in water is OK as they work better when wet. TRUE or FALSE 5) It is ok to place an item in the way of a fire exit as long as you remove it within 24hrs. TRUE or FALSE 6) Every injury must be reported to your supervisor AND Advantage Recruitment. TRUE or FALSE 7) If an object is too difficult to handle, you should use mechanical aids or ask for help. TRUE or FALSE 8) Drugs and Alcohol are prohibited in work places. TRUE or FALSE 9) It is OK to enter a confined space if you don’t hold a confined space ticket, as long as you are very careful and have seen someone do it before. TRUE or FALSE 10) Your shift has finished, but just before you leave you spill something on the floor, you should: ) Ask a workmate to please clean it up when they get a spare minute. b) Immediately display ‘Caution, wet floor’ sign, clean up the mess thoroughly and ensure the area is safe before you leave. c) Leave it for someone else to clean up and hope that no one notices it was you that made the mess in the first place. 11) What does MSDS stand for? a) Material Safety Data Sheet b) Mass Storage Device System c) Manual System of Dangerous Substances 12) If you find one of your co-workers being electrocuted, what should you do? a) Call for assistance and wait for the electrocution to cease. b) Don’t touch the person, isolate the supply and obtain assistance ) Pull the person away from the electrocution device, pour water over it in order to eliminate the chance of it catching on fire, then seek assistance for your co-worker. 13) What does PPE stand for? a) Professional Paid Employment b) It does not stand for anything. It is another name for a hard hat. c) Personal Protective Equipment 14) Under what circumstance can you remove your hearing protection when in a noisy area that has signs posted stating hearing protection must be worn? a) If you are talking to a fellow employee and are having troubles hearing them. b) If it starts to get uncomfortable, as all safety equipment should fit comfortably. ) Under no circumstance. Removing your hearing protection in a noisy environment for even a short amount of time can cause damage. ? BIBLIOGRAPHY: I thank the following people for providing valuable information guidance WEBSITES : 1) http://en. wikipedia. org/wiki/Godrej_Group 2) www. godrej. com 3) http://www. new. godrej. com/godrej/GodrejAppliances/index. aspx 4) www. godrejinfotech. com Legal Core Group  ¦ Safety Dept  ¦ Maintenance Dept  ¦ Paint Shop  ¦ Stores Disposal Dept. OHS Head Employee Rep Head Legal Core Group Assoc. Mgr Safety CFS Head – Safety Committee Vice President Division Head (Security Equipment Division) DEB Exec. Director President PDL SAFETY INSPECTION Inspection should be carried out after every one or two section by management team. Safety officer/engineer should have an inspection of every section on every day. Preparation of safety inspection report explaining to concerned engineer/supervisor submission of that report to the section manager. Fatal accident Reportable accidents Non Reportable Accidents Near misses or First Aid Shrinking the base by eliminating Unsafe behaviours and †¦Ã¢â‚¬ ¦Ã¢â‚¬ ¦ †¦ Shrinking the height by establishing Inherently safer processes and 1 30 300 3,000 30000 Hazards : Unsafe Act Unsafe Condition